Forming three-dimensional (3d) electronic parts

Abstract

In an example method for forming three-dimensional (3D) printed electronic parts, a build material is applied. An electronic agent is selectively applied in a plurality of passes on a portion of the build material. A fusing agent is also selectively applied on the portion of the build material. The build material is exposed to radiation in a plurality of heating events. During at least one of the plurality of heating events, the portion of the build material in contact with the fusing agent fuses to form a region of a layer. The region of the layer exhibits an electronic property. An order of the plurality of passes, the selective application of the fusing agent, and the plurality of heating events is controlled to control a mechanical property of the layer and the electronic property of the region.

What is claimed is: 
     
         1 . A method for forming three-dimensional (3D) printed electronic parts, the method comprising:
 applying a build material;   selectively applying an electronic agent in a plurality of passes on a portion of the build material;   selectively applying a fusing agent on the portion of the build material;   exposing the build material to radiation in a plurality of heating events;   wherein:
 during at least one of the plurality of heating events, the portion of the build material in contact with the fusing agent fuses to form a region of a layer; and 
 the region of the layer exhibits an electronic property; and 
   controlling an order of the plurality of passes, the selective application of the fusing agent, and the plurality of heating events to control a mechanical property of the layer and the electronic property of the region.   
     
     
         2 . The method as defined in  claim 1  wherein:
 the portion of the build material is less than all of the build material; 
 the method further comprises:
 selectively applying the fusing agent on an other portion of the build material; and 
 selectively applying a detailing agent on the other portion of the build material; 
 
 during at least one of the plurality of heating events, the other portion of the build material in contact with the fusing agent fuses to form a remaining region of the layer; and; 
 the detailing agent controls a maximum temperature at which the other portion of the build material fuses. 
 
     
     
         3 . The method as defined in  claim 1  wherein:
 the portion of the build material is less than all of the build material; 
 the method further comprises selectively applying a detailing agent on an other portion of the build material; 
 the detailing agent controls a maximum temperature that the other portion of the build material achieves; and 
 the other portion of the build material in contact with the detailing agent does not fuse. 
 
     
     
         4 . The method as defined in  claim 1  wherein the selectively applying of the electronic agent in the plurality of passes, the selectively applying of the fusing agent, and the exposing of the build material to radiation in the plurality of heating events occur prior to an application of additional build material. 
     
     
         5 . The method as defined in  claim 1 , further comprising selectively applying an activating agent in a plurality of passes on the portion of the build material, wherein the activating agent includes a chloride salt, a bromide salt, or an iodide salt. 
     
     
         6 . The method as defined in  claim 1 , further comprising cooling the build material to a threshold temperature after at least one of the plurality of heating events and prior to at least one other of the plurality of heating events. 
     
     
         7 . The method as defined in  claim 6  wherein the build material is a polymeric build material, a ceramic build material, a metallic build material, or a composite build material, and the threshold temperature ranges from about 10° C. to about 100° C. below a melting point the build material. 
     
     
         8 . The method as defined in  claim 2  wherein each of the selectively applying of the electronic agent, the selectively applying of the fusing agent, and the selectively applying of the detailing agent is accomplished in at least one printing pass by thermal inkjet printing, piezoelectric inkjet printing, or continuous inkjet printing. 
     
     
         9 . The method as defined in  claim 8  wherein:
 at least one of the plurality of heating events is accomplished prior to at least one of the selectively applying of the electronic agent or the selectively applying of the fusing agent; and 
 at least one other of the plurality of heating event is accomplished subsequent to the at least one printing pass. 
 
     
     
         10 . The method as defined in  claim 2  wherein the detailing agent is tinted with a colorant. 
     
     
         11 . The method as defined in  claim 1  wherein the electronic agent includes metal nanoparticles, a carbon conductor, a conductive polymer, or a metal organic decomposition salt. 
     
     
         12 . A method for forming three-dimensional (3D) printed electronic parts, the method comprising:
 applying a build material;   selectively applying an electronic agent in a plurality of passes on a portion of the build material;   selectively applying an activating agent in a plurality of passes on the portion of the build material;   exposing the build material to radiation in a plurality of heating events;   wherein:
 during at least one of the plurality of heating events, the portion of the build material in contact with the electronic agent and the activating agent fuses to form a region of a layer; and 
 the region of the layer is exhibits an electronic property; and 
   controlling an order of each of the plurality of passes and the plurality of heating events to control a mechanical property of the layer and the electronic property of the region.   
     
     
         13 . The method as defined in  claim 12  wherein:
 the portion of the build material is less than all of the build material; 
 the method further comprises:
 selectively applying a fusing agent on an other portion of the build material; and 
 selectively applying a detailing agent on the other portion of the build material; 
 
 during at least one of the plurality of heating events, the other portion of the build material in contact with the fusing agent fuses to form a remaining region of the layer; and; 
 the detailing agent controls a maximum temperature at which the other portion of the build material fuses. 
 
     
     
         14 . The method as defined in  claim 12  wherein the activating agent includes a chloride salt, a bromide salt, or an iodide salt. 
     
     
         15 . A three-dimensional (3D) printing system, comprising:
 a supply of build material;   a build material distributor;   a supply of an electronic agent;   a first applicator for selectively dispensing the electronic agent;   a supply of an activating agent;   a second applicator for selectively dispensing the activating agent;   a supply of a fusing agent;   a third applicator for selectively dispensing the fusing agent;   a supply of a detailing agent;   a fourth applicator for selectively dispensing the detailing agent;   at least one fusing lamp;   a controller; and   a non-transitory computer readable medium having stored thereon computer executable instructions to cause the controller to:
 utilize the build material distributor to dispense the build material; 
 utilize the first applicator and the second applicator to respectively and selectively dispense in a plurality of passes the electronic agent and the activating agent; 
 utilize the third applicator and the fourth applicator to respectively and selectively dispense the fusing agent and the detailing agent; and 
 utilize the at least one fusing lamp to expose the build material to radiation in a plurality of heating events to form a three-dimensional part having an electronic property.